High-performance chamber mixer for catalytic oil suspensions as a reactor for the depolymerisation and polymerisation of hydrocarbon containing residual substances to middle distillate in the cycle

ABSTRACT

The invention involves the optimization of the input and output systems for a high-performance chamber mixer, in which the actual decomposition of the residual substances in middle distillate and inorganic residues is effected.

The present invention relates to a method for producing Diesel oil fromhydrocarbon containing residual substances in an oil cycle with soliddeposition and product distillation for the Diesel product.

In the previously mentioned patent specification, the components of theinput and output are dealt with only in general manner. The goal of thesupplementary application is to precisely describe these components andto explain them in an embodiment. These precisions become possible sincethe high-performance chamber mixer is able to produce a high negativepressure, and thus all of the input problems can be solved basedthereon. An embodiment of the present invention is described in moredetail below by way of the drawings. There show:

FIG. 1 a schematic representation of a plant for performing the methodaccording to the invention;

FIG. 2 a schematic representation of the plant of FIG. 1.

By way of FIG. 1, first, the method is explained. For the purpose of aclogging-free input, on the suction side of a high-performance chambermixer 1, an input container 2 having three input openings is disposed.At the upper end of the input container 2 there is the first inputopening, the residual substance input 4, which adjoins the inputcontainer 2 through an input system 3 acting in crushing and meteringmanner.

The substances to be input, residual substance dry 5, residual oil fromthe plant or as a residual substance 6, lime or soda as a neutralisingagent 7 and the catalyst 8 in the mixing hopper 9, enter this inputsystem 3 through the hopper 9 and the collecting container 4. Both thehopper 9 and the collecting container 4 are equipped with vibratorsensuring continuous inflow.

The other two openings at the input container 2 are a cycle catalyst oilsupply 10 from an oil collection container 15 and a collection catalystoil supply 11 from an oil collection container 15 disposed at thedischarge of this oil collection container 15. Thereby, it is madepossible that the catalyst oil also retains the lime residues in thecycle.

On the pressure side of the high-performance chamber mixer 1, a pressureline 12 is attached. It passes the product vapour-oil mixture producedin the high-performance chamber mixer 1 into an evaporator 14. It has adistribution gutter 13 dividing the entering oil-vapour mixture into aplurality of partial jets through perforated sheets in an annular nozzlewith open end, which wet the wall, and which results in a surface of theliquid in the evaporator 14 as large as possible.

Thereby, it is achieved that almost the entire product separates invaporous state from the liquid and is able to deposit upwards in adistillation column 18, and no product will enter the oil collectioncontainer 15, if possible. Repeated cleavage of already generatedproduct in the Diesel boiling region would reduce the production amountand decrease the product in quality.

The input system 3 is turned on and off and speed controlled by a levelcontrolling container 16 indicating and controlling the level in the oilcollection container 15, respectively. At the lower end of the levelcontrolling container 16, a pump 17 is disposed, which passes a smallamount of oil to the input system 3 in order to protect it fromobstructions.

On the vapour side of the product, the product vapour is purified fromthe entrained oil particles by fractioned distillation in thedistillation column 18 and condensed in the condenser 19. The waterportions arising in the condensation are retained in the condenser 19 bya partition on the input side due to their higher specific gravity.

From there, the water portion enters a pH measuring container 20 byexchange with the product located there with the water settlingdownwards. In the pH measuring container 20, there is a pH measuringprobe 23 and a conductivity probe 22. Upon reaching the water at theconductivity probe 22, a certain amount of water is discharged into aproduct water container 21 and from there discharged into an overflowpipe.

The lighter product, Diesel or fuel oil, enters a product line 24 on theoutput side through the separating sheet in the condenser, whereinvaporous product portions enter a product container 25 through a line 26like the product in the product line 24. A small portion of the productgets back in controlled manner into the distillation column into one ofthe upper bases 27 through the line 25.

Therein, the control is adjusted such that the amount controls thereturn in the column. It generates a different product quality forsummer Diesel with an average boiling temperature of 290° C., for winterDiesel with an average boiling temperature of 270° C., and for kerosenewith an average boiling temperature of 240° C. Cooling the condenser iseffected with cycle water and a heat exchanger 38 with cycle water pump.

Behind the product container, there is a vacuum pump 37 which keeps theentire system under negative pressure. The sucked gas is added in thecurrent generator as intake air or purified in a catalytic exhaust airpurification. As gases sucked off from the plant, the carbon dioxidesderived from the biologic substances and the small gas amounts possiblyderived from leaks result.

Thereby, it is ensured that no combustible product can exit the plant.To this end, the vacuum pump controls the amount of input and the amountof output of the non-reactive, inorganic residues discharged at thelower end of the plant.

The non-reactive portions of the input substance and the salts formingby the ion-exchanging catalyst and the added lime or soda enter a heatchamber 32 through a control valve 30 and a hot sludge pump 31.

It is electrically heated to 550° C. and has a heat-resistantevaporation container with the sludge entry on the inner side, a vapourreturn line to the evaporator and a screw output 33 for the heatedinorganic substances entering a residual container 34. On average, it is1 to 3% of the input substance.

The substances collected in the residual container 34 are subsequentlymixed with the water of the container 21. The substances depositing inthe suspension, metal, glass and ceramics, are separated and thesuspension is filtered. The filter residue is re-utilisable catalyst.The liquid contains the formed salts and is passed into the waste water.

The containers have relieve and pressure balance lines like the inputcontainer 2 connected to the distillation column through a vent chamberwith check valve 35. Furthermore, all of the heat carrying parts aredoubly isolated with an alumina fibre mat on the surface and anisolating mat thereon. On the outside, a cover sheet is disposed, whichis formed as a closed chamber on the turbine, which can withstand asmall overpressure.

In one embodiment, the method is explained. A high-performance chambermixer 1 with an electrical power of 200 kW sucks the solids from acollection container 2 having a volume of 800 l from the Correau pump ofthe Correau Paris, a crushing and metering gear pump of 37 kW. Thecontainer located above has a capacity of 2 m³. The connecting line isDN50.

The connecting lines between the collection container 2 and the oilcollection container 15 are relatively small to allow a high mixingaction in the collection container with high oil exit speed andcontrolled negative pressure. They have a diameter of 1.5 inch andvalves controlling the negative pressure in the collection container 2depending on the material located at the input 3. The relieve line withcheck valve 36 has a diameter of ¾ inch.

The evaporation container 14 has a capacity of 2 m³ and a distributiongutter 13 with a width of 80 mm and three rows of holes with a holediameter of 8 mm, wherein the inner and outer row of holes have inclinedbores from the centre towards the wall and the interior space. The oilcollection container 15 disposed below has a volume of 1.5 m³ and thelevel container has a volume of 100 litres.

The distillation column 18 has 15 bubble trays with each 52 bubble capshaving a diameter of 600 mm. The condenser 19 has a volume of 300litres. The output system has the control valve 30 DN50 with a hotsludge pump without plastic parts, and is connected to the heat chamber32, a heating furnace of the company Nabertherm with 15 kW power, and avapour pipe 35 to the evaporator 14 with a diameter of 1.5 inch,isolated and provided with condensation loops.

The residual output 33 is a screw having a diameter of 200 mm and aclosure envelope over the connection from the residual container 34 witha volume of 1 m³. The line to the pH container 20 has a diameter of 1.5inch and the pH container has a volume of 0.5 m³ with conductivitysensor 22 and pH gauge 23. The water collection container 21 has avolume of 1 m³.

The device for performing the method is explained by way of FIG. 2. Onthe suction side of the high-performance chamber mixer 101, an inputcontainer 102 is disposed, which has input openings. At the upper end ofthe container, there is the first input opening, the residual substanceinput 104 adjoining the input container 102 through an input system 103having gears and a metering insert.

The input openings, residual substance dry 105, residual oil from theplant or as a residual substance 106, lime or soda as neutralising agent107 and a catalyst 108 in the mixing hopper 109 are connected to theinput system 103 through a hopper 109 and a collection container 104.Both the hopper 109 and the collection container 104 are equipped withvibrators.

The other two openings at the input container 102 are the cycle catalystoil supply 110 from an oil collection container 115 and the collectioncatalyst oil supplies 111 from an oil collection container 115 disposedat the discharge of this oil collection container.

A pressure line 112 is attached on the pressure side of thehigh-performance chamber mixer 101. It connects the high-performancechamber mixer 101 to an evaporator 114. It has a distribution gutter 113provided with perforated sheets in an annular nozzle with open end onthe inner side.

The supply system 103 is connected to a level controlling container 116.It contains a level probe. At the lower end of the level controllingcontainer 16, a pump 117 is disposed, which has a connecting line to theinput system 103.

The evaporation container 114 is connected to the distillation column118. At the upper end of the distillation column 118, the condenser 119is disposed, which has a partition inside. The condenser 119 has aconnection to a pH measuring container 120 on the input side. Aconductivity probe 122 is attached in the container, which iselectronically connected to a water drain valve.

On the side of the condenser opposing the input side, lines 124 and 126are attached at the bottom and at the top, which are connected to aDiesel product container 125. An adjusting valve 128 is disposed in theline 124, which is connected to a connecting line to the distillationcolumn. The adjusting valve is communicated with an electronic control,which is set to a temperature measurement. This control has theindications Summer Diesel, Winter Diesel and kerosene.

On the cooling side, the condenser 19 is connected to a heat exchanger138 with cycle water pump. After the product container, there is avacuum pump 137, which is thereby connected to all of the parts of theplant.

At the lower end of the oil collection container 115, the residualoutput valve 130 is disposed. It is connected to a hot sludge pump 131and a heat chamber 132. It is located in an electrically heated furnaceand has a vapour output 135 besides the input from the hot sludge pump131.

This line is also isolated and has condensate loops with drain cocks andterminates in the evaporator container 114. The heat chamber 132 has adischarge screw 133 on the output side, which is connected to an ashcontainer 134.

A suspension chamber follows the residual container 134, which has aconnecting line to the water container 121 and has two outputs. The oneoutput at the upper side is connected to a filter press suitable forcatalyst sludge, and the lower side is connected to a reusable materialcontainer for ceramics, metal and glass.

The containers have relieve and pressure balance lines as the inputcontainer 102 connected to the distillation column through a ventingchamber with check valve 135. Furthermore, all of the heat carryingparts are doubly isolated with an alumina fibre mat on the surface andan isolating mat thereon. On the outside, a cover sheet is disposed,which is formed as a closed chamber on the turbine, which can withstanda small overpressure.

In one embodiment, the device is explained. A high-performance chambermixer 101 with an electrical power of 200 kW has a connecting line to acollection container 102 having a volume of 800 l. It has an upwardsconnecting line to the Correau pump of the company Correau Paris, acrushing and metering gear pump of 37 kW. The container located abovehas a capacity of 2 m³. The connecting line is DN50.

The connecting lines between the collection container 102 and the oilcollection container 115 are relatively small and have a diameter of 1.5inch and valves controlling the negative pressure in the collectioncontainer 102 depending on the material located at the level of theinput 103. The relieve line with check valve 136 has a diameter of ¾inch.

The evaporation container 114 has a capacity of 2 m³ and a distributiongutter 113 having a width of 80 mm and three rows of holes with a holediameter of 8 mm, wherein the inner and outer row of holes have inclinedbores from the middle towards the wall and the interior space. There oilcollection container 115 disposed below has a volume of 1.5 m³ and thelevel container has a volume of 100 litres.

The distillation column 118 has 15 bubble trays with each 52 bubble capswith a diameter of 600 mm. The condenser 19 has a volume of 300 litres.The output system has the control valve 30 DN50 with a hot sludge pumpwithout plastic parts and is connected to the heat chamber 132, aheating furnace of the company Nabertherm with 15 kW power, and a vapourpipe 135 to the evaporator 114 with a diameter of 1.5 inch, isolated andprovided with condensation loops.

The residual output 133 is a screw with a diameter of 200 mm and aclosure envelope over the connection from the residual container 134with a volume of 1 m³. The line to the pH container 120 has a diameterof 1.5 inch and the pH container has a volume of 0.5 m³ withconductivity sensor 122 and pH gauge 123. The water collection container121 has a volume of 1 m³.

DESCRIPTION OF FIGURES FIG. 1

-   1 High-performance mixer-   2 input container-   3 input openings-   4 residual input-   5 residual substance-   6 residual substance-   7 residual substance-   8 residual substance-   9 hopper-   10 cycle catalyst oil supply-   11 collection catalyst oil supply-   12 pressure line-   13 distribution gutter-   14 evaporator-   15 oil collection container-   16 level control-   17 pump-   18 distillation column-   19 condenser-   20 pH measuring container-   21 product line-   22 conductivity probe-   23 pH measuring probe-   24 product line-   25 product container-   26 line-   27 base-   28 return valve-   29 residual space in the oil collection container 15-   30 control valve-   31 hot sludge pump-   32 heat chamber-   33 screw output-   34 residual container-   35 check valve-   36 check valve-   37 vacuum pump-   38 heat exchanger

FIG. 2

-   101 High-performance mixer-   102 input container-   103 input system-   104 input openings-   105 residual substance-   106 residual substance-   107 residual substance-   108 residual substance-   109 mixing hopper-   110 cycle catalyst oil supply-   111 collection catalyst oil supply-   112 pressure line-   113 distribution gutter-   114 evaporator container-   115 oil collection container-   116 level control container-   117 pump-   118 distillation column-   119 condenser-   120 pH measuring container-   121 water collection container-   122 conductivity probe-   123 pH gauge-   124 lines-   125 Diesel product container-   126 lines-   127 return base in distillation-   128 disk valve-   129 residual space in the oil quick container 15-   130 residual output valve-   131 hot sludge pump-   132 heat chamber-   133 discharge container-   134 ash container-   135 vapour output-   136 check valve-   137 vacuum pump-   138 heat exchanger

1. Method for producing Diesel oil from hydrocarbon containing residualsubstances in an oil cycle with solid deposition and productdistillation for the Diesel product, characterized in that thehigh-performance chamber mixer (1) is connected to a special inputcontainer (2) on the suction side and to a four-jet evaporator (14) onthe pressure side.
 2. Method according to claim 1, characterized in thatthe input container (2) has a closing, crushing input pump on theresidual matter input side, and is connected to two lines from and belowthe oil collection container (15) on the oil side.
 3. Method accordingto claim 1, characterized in that a distillation column is attached onthe evaporator.
 4. Method according to claim 1, characterized in thatthe oil collection container is collected to a heat chamber through apump, which heats the residue to complete evaporation of thehydrocarbons at 450 to 500° C.
 5. Device for performing the methodaccording to claim 1, characterized in that a chamber shaft mixer (101)has a collecting line to an input container (102) on the suction side,and is connected to evaporator gutters (113) of the evaporator (114) onthe pressure side.
 6. Device according to claim 5, characterized in thatthe chamber shaft mixer (101) is doubly isolated and has an oil-tightouter envelope around an isolation.
 7. Device according to claim 5,characterized in that the oil collection container (115) collected tothe input container (102) has a controllable output valve collected to acontainer in a heat chamber through a hot sludge pump.
 8. Deviceaccording to claim 7, characterized in that the heat chamber is heatedby an electrical heating furnace, which reaches at least 550° C., andhas connecting lines from the heat chamber to the evaporation container(113) and the ash container (134) through an output screw (133).